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REMOVAL & INSTALLATION

2.3L and 2.5L Engines
  1. Drain the cooling system.
  2. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  3. Remove or disconnect the following:
  4. Align the engine timing marks at Top Dead Center (TDC) for No. 1 cylinder. Remove the timing belt.
  5. Position a piece of wood on a floor jack and raise the engine carefully as far as it will go. Place blocks of wood between the engine mounts and crossmember pedestals.
  6. Removeamshaft by carefully withdrawing it toward the front of the engine. Caution should be used to prevent damage to cam bearings, lobes and journals.
  7. Check the camshaft journals and lobes for wear. Inspect the cam bearings, if worn (unless the proper bearing installing tool is on hand), the cylinder head must be removed for new bearings to be installed by a machine shop.

    To install:

  8. Install or connect the following:
  9. Fill the cooling system.
  10. Start the engine and check for leaks, repair if necessary.
3.0L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Properly relieve the fuel system pressure.
  3. Drain the cooling system.
  4. Drain the engine oil.
  5. Evacuate the A/C system.
  6. Remove or disconnect the following:
  7. Rotate the crankshaft so that No. 1 piston is at Top Dead Center (TDC) on the compression stroke.
  8. Turn the engine by hand to TDC of the power stroke on No. 1 cylinder.
  9. Matchmark the rotor, distributor body and engine. Disconnect the distributor wiring harness and remove the distributor, if equipped.
  10. Carefully slide the camshaft out of the engine block, using caution to avoid any damage to the camshaft bearings.

    To install:

  11. Oil the camshaft journals and cam lobes with heavy SJ engine oil (50W). Install the spacer ring with the chamfered side toward the camshaft, then insert the camshaft key.
  12. Install or connect the following:
  13. Rotate the camshaft and crankshaft as necessary to align the timing marks. Install the camshaft gear and chain. Torque the bolt to 46 ft. lbs. (62 Nm).
  14. Coat the tappets with 50W engine oil and place them in their original locations.
  15. Apply 50W engine oil to both ends of the pushrods. Install the pushrods in their original locations.
  16. Pivot the rocker arms into position. Torque the fulcrum bolts to 96 inch lbs. (11 Nm).
  17. Rotate the engine until both timing marks are at the top of their sprockets and aligned. Torque the following fulcrum bolts to 18 ft. lbs. (24 Nm):
    1. No.1 intake.
    2. No.2 exhaust.
    3. No.4 intake.
    4. No.5 exhaust.
  18. Rotate the engine until the camshaft timing mark is at the bottom of the sprocket and the crankshaft timing mark is at the top of the sprocket, and both are aligned. Torque the following fulcrum bolts to 18 ft. lbs. (24 Nm):
    1. No.1 exhaust.
    2. No.2 intake.
    3. No.3 intake and exhaust.
    4. No.4 exhaust.
    5. No.5 intake.
    6. No.6 intake and exhaust.
  19. Torque all the bolts to 24 ft. lbs. (33 Nm).
  20. Turn the engine by hand to 0 degrees Before Top Dead center (BTDC) of the power stroke on No. 1 cylinder.
  21. Install or connect the following:
  22. Recharge the A/C system.
  23. Refill the cooling system.
  24. Replace the oil filter and refill the engine with the specified amount of engine oil.
  25. Start the engine and check the ignition timing and idle speed. Adjust if necessary. Run the engine at fast idle and check for coolant, fuel, vacuum or oil leaks.
4.0L OHV Engine

NOTE: It is necessary to replace the oil pan gasket when removing and installing the engine front cover. It will also be necessary to remove the transmission to properly reseal the oil pan.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Drain the engine oil.
  3. Drain the cooling system.
  4. Evacuate the A/C system.
  5. Relieve fuel system pressure.
  6. Remove or disconnect the following:
  7. Turn the engine by hand until the timing marks align at Top dead Center (TDC) of the power stroke on No.1 piston.
  8. Place the timing chain tensioner in the retracted position and install the retaining clip.
  9. Check the camshaft end-play. If excessive, you'll have to replace the thrust plate.
  10. Remove the camshaft gear attaching bolt and washer, then slide the gear off the camshaft.
  11. Remove the camshaft thrust plate.
  12. Carefully slide the camshaft out of the engine block, using caution to avoid any damage to the camshaft bearings.

    To install:

  13. Lubricate the camshaft using a good assembly lubricant.
  14. Install or connect the following:
  15. Rotate the camshaft and crankshaft, as necessary, to align the timing marks.
  16. Remove the clip from the chain tensioner
  17. Coat the tappets with 50W engine oil and place them in their original locations.
  18. Apply 50W engine oil to both ends of the pushrods. Install the pushrods in their original locations.
  19. Fill the cooling system.
  20. Recharge the A/C system.
  21. Replace the oil filter and refill the engine with clean oil.
  22. Start the engine and check the ignition timing and idle speed; adjust if necessary. Run the engine at fast idle and check for coolant, fuel, vacuum or oil leaks.

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